Yamaha TW200 (2001+) Maintenance Schedule and Service Intervals

This is the maintenance schedule and associated service intervals for the Yamaha TW200 from 2001 onward — the “second gen”, updated from the first gen.

The TW200 is (or was) one of the last “farm bikes”. It was originally launched in 1987, and still available in some parts of the world, like the US, despite — or because of — its ancient design.

In its over three decades of life of the Yamaha TW200, the only external change has been to remove a kickstarter, and to replace the front drum brake with a disc brake. The rear brake is still a drum brake.

Since 2001, there have been some minor changes to the maintenance. For example, the 2001+ model has a spark arrester, and no longer requires the cam chain to be inspected.

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What you need for a basic service on the Yamaha TW200

Servicing the Yamaha TW200 is very easy. It has a single cylinder and everything is fully exposed. Plus, it’s a lightweight motorcycle, which helps when moving it around the garage.

PartYamaha TW200 spec
Engine oilThe manual specifies a range of engine oils depending on operating temperature. Yamalube 10W-40 covers most normal temperatures (from 10 F to 110F, or -10 C to 45 C).
Oil filterThe TW200 takes a HF143 oil filter from Hiflofiltro.
Spark plugThe TW200 takes an NGK DR8EA spark plug. The gap is 0.6-0.7mm.
Air filterYou can often clean the air filter. But replace it with a YA-2002 when you need to.
Brake fluidUse Castrol DOT 4 brake fluid.
Chain lubeUse Motul chain paste or another high-quality chain lubricant.
General greaseUse lithium soap-based grease for external pivot points.
Yamaha TW200 general maintenance parts

2001+ Yamaha TW200 Maintenance Schedule

Below is the maintenance schedule for the Yamaha TW200 made from 2001 onward.

The original maintenance schedule was made up of multiple parts (Emission-related and other), but they’re combined and simplified here.

Notes

  • General maintenance service intervals for the TW200 is every 3000 miles of every 5000 km. You change the oil at every service and inspect a bunch of things (including valve clearance), and then change filters and other items every second service.
  • There are some time-based intervals, like changing brake fluid every 2 years.
mi x 10000.647101316
km x 10001611162126
months1612182430Every
Change engine oil — Yamalube 10W40 (warm engine before draining).
Clean engine oil filter element
Clean engine oil strainer
Check spark plug condition, adjust gap and clean
Replace spark plug (NGK DR8EA)
Clean air filter with solvent (K&N air filter cleaning kit). Replace if necessary (YA-2002),More often if riding in dust/rain
Check and adjust valve clearance when engine is cold
Check and adjust engine idle speed
Check chain slack/alignment and condition. Adjust and thoroughly lubricate chain (Motul Chain Paste)300 mi / 500 km, or if it gets wet/dirty
Check fuel hoses for cracks or damage. Replace if necessary
Check clutch operation. Adjust or replace cable.
Lubricate control and meter cables (Protect all cable life)
Check throttle grip operation and free play. Adjust the throttle grip free play, and adjust if necessary. Lubricate the throttle grip housing.
Check front brake operation, fluid level, and for fluid leakage. Adjust break lever free play and replace brake pads if necessary
Check rear brake operation. Adjust cable and replace brake shoes if necessary.
Check brake hoses for cracks or damage, and for correct routing and clamping
Change brake fluid (Castrol DOT 4), and rubber parts of master cylinder/caliper2 years
Replace brake hoses4 years
Check wheels for runout, spoke tightness and for damage. Tighten spokes if necessary.
Check tire tread depth and for damage. Replace if necessary.
Check wheel bearings for smooth operation. Replace if necessary.
Check swingarm bush assemblies for looseness. Lubricate with lithium soap-based grease until new grease shows.
Check steering bearing assembly for looseness.
Repack steering bearings (Lithium soap-based grease)
Check all chassis fittings and fasteners. Correct if necessary.
Lubricate brake lever pivot shaft with silicone grease lightly.
Lubricate clutch lever and brake pedal pivot shafts with lithium soap-based grease lightly.
Check sidestand pivot operation. Apply lithium-soap-based grease lightly as necessary
Check sidestand switch operation and replace if necessary.
Check front fork operation and for oil leakage. Rebuild / replace if necessary.
Check rear shock operation and for oil leakage. Rebuild / replace if necessary.
Check operation of front and rear brake switches
Check operation of lights, signals, and switches.
Adjust headlight beam.
Clean spark arrester
Check crankcase breather hose for cracks and damage. Replace if necessary
Check exhaust system for leakage. Tighten and/or replace gaskets as necessary.
Check evap control system (if fitted) for damage. Replace if necessary
Check battery specific gravity and breather hose for proper operation.
Maintenance schedule for the Yamaha TW200 (2001+)

Tyres and tyre pressures for the Yamaha TW200

Below are the tyre sizes and pressures that the manual specifies.

The TW200 shipped most recently with Bridgestone TW31/34 tires.

WheelTyre (Tire) sizeTyre (Tire) pressure (cold)
Front130/80-18 M/C 66 P125-150 kPa / 1.25-1.5 bar / 18-22 psi
Rear180/80-14 M/C 78 P125-175 kPa / 1.25 – 1.75 bar / 18-25 psi
Tyre sizes and pressures — TW200

About the Yamaha TW200

2004 Yamaha TW 200
2004 Yamaha TW200

The Yamaha TW200 is a very versatile motorcycle, in a class of bikes often known as “farm bikes”, “beach bikes”, or maybe “scramblers”. It has off-road capability, decent on-road behaviour (at less than highway speeds), and a lot of heritage style.

The Yamaha TW200 is powered by a 196cc air-cooled SOHC 2-valve 4-stroke single with plenty of low-and mid-range torque. The bike is similar in class to the Suzuki VanVan 200, though the TW200 has a broader following.

It has a low seat and fat tyres that give it a very smooth ride over a wide variety of terrain. Whether you’re a beginner rider, a veteran, a camper, or a city commuter, this bike has a use.

The Yamaha TW200 is quite basic in spec, but that’s intentional. The engine, for example, is fed by carburettor, in a time when many of its competitors moved to fuel injection. The rear brake is a drump, and the suspension is of a conventional sort and non-adjustable.

But the TW200’s value is in its simplicity. It’s very easy to repair and service, for example. Even though the Yamaha TW200 has service intervals of 3000 miles (5000 km) at which you have to inspect the valve clearance, there are only two valves in the one cylinder and they’re very accessible.

The Yamaha TW200 even has some advantages over its dirt bike brethren. It has a very low seat height, and it comes with a bash plate.

However, it’s due to competition with the dirt bikes (with their higher-spec components and engines, longer-travel suspension, etc.) that the TW200 hasn’t been updated in two decades and has been discontinued in most markets.

Manual for the Yamaha TW200

The above information was gleaned from the owner’s manual for the Yamaha TW 200.

Shown below are the user manuals for the 2001 and the 2018 models of TW200. The maintenance schedule is the same.

Maintenance schedule from 2001 Yamaha TW200
Maintenance schedule from 2001 Yamaha TW200
2018-2019 Yamaha TW200 Maintenance schedule screenshot from manual
Maintenance schedule from 2018 TW200 manual

You can download the maintenance schedule for the Yamaha TW200 from Yamaha’s website here.

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